HoneyBadger
Rising Sun Member
Yep.Devil
It literally hurts my soul every day that I can't do a SAS... Just saying.
Yep.Devil
Yep.
It literally hurts my soul every day that I can't do a SAS... Just saying.
LOL. Not that you'd want to, but I think you are having the exact same issue I was with my old truck. With the old one, on 33's, it didn't break, it didn't have issues, it was fun and I did all of the trails I wanted (like in the video).
Then I went to 35's and it fell apart, so I went to the SAS. And again, totally different situation, but for me, it was so much money that I ended up having to part things out because it wasn't ever going to get finished. I think I was into it maybe 8k by the time I quit. I was able to sell the bits and make back most of it, but thats not everyones situation for sure. There are of course much less expensive ways to do it.
I'm PMing you some more info.
Did you go with a MONSTER build? Now I'm nervous that my cost estimates are off...
Not sure what you mean by monster. Mine was links front and rear, King coilovers up front (got those used), king shocks in back with some form of coil (never got to tuning it so I'm not sure). FJ80 axle up front to get the correct width, Hellfire knuckle system to get the FJ80 high steer, ARB with 4.88's in a high pinion diff, High angle driveline driveshaft with one of their good joints. I cut the frame off just in front of the front body mounts so that I could raise it up, to try to keep the frame height on 37's around 20-21", tires and wheels, etc, etc, etc.
What you have talked about in this thread, given you have an axle and a number of parts, won't be that bad.
You probably have 600 bucks in axles, up to a couple hundred in front end rebuild parts depending on how the bearings, seals, wipers, knuckles, etc are in the axle, and whether you go with Japanese (best) or Chinese (not the best) stuff to rebuild. You need high steer, which is about 400 bucks the last time I looked, buy maybe its less now.
so 1200 ish to get the axle up and running. Less if you use stock birfields, though you aren't gaining much strength over your CV's with those, if any. But you can certainly drop the cost there.
The diffs, from what you mentioned, will cost. ARB's are running 950 on average these days (some places cheaper some places more, and there are sales and things that come up). Gears I have seen as cheap as 200 a set, and I don't know on install kits (i'm thinking 100 bucks for that? Not sure there). And then you have to have them installed. Robbie put an ARB (no gear change) in my front for 300 bucks. The 8" diffs are much easier to install, but with the gear set up, that is probably a good number.
So, 1900 ish for the lockers, 400 for gears, 200 for the kits, and 600 in labor looks like 3100 bucks for diffs. I mention Robbie simply because he does absolutely excellent work, and he stands behind it, so any issues he takes care of you, and he is local. You may be able to order built diffs for less, though Marlin is 1650 per diff, so thats 3200 bucks, Trail Mart is 1521, so only slightly less, and you have shipping. Again, those are just estimates for the labor and kit costs, I have no idea on that. May be other places that are cheaper, but you also want to look at what they use for bearings and parts.
You also mentioned dual cases, which is smart since you have to have a new front driveline made for the SAS anyway, and that would increase the cost. However, could certainly be dropped to save money.
So, with an axle rebuild, steering, and the lockers/gears you talked about, assuming you can source the other parts from a yard or something, and if we round the diffs off to 3k, you are looking at 4300 bucks, if you include a respline for the front shaft to get the travel you need for the SAS. You also wanted to up your tires. Depending on what you go with, you could be at 1000-1500 ish (by the time you do taxes, mount, and balance. So 5300-5800.
My issue wasn't the big ticket items. Mine was the equivalent of the "nickel and dimed to death" syndrome. I don't recall where that saying came from, but it applied to my build. The difference was it was actually 50 and 100 dollaring me to death. I would have things like "crap I need hardware for the links, there's 75 bucks", "crap, I need my driveline extended, there's 100 bucks", crap I need new trunion bearings, there's some amount of money (forgot what those were". I got sick of it and decided to go back to basics with a 99 4runner.
Now, before people get all bent out of shape and say that I've DRASTICALLY overpriced things, I have put in this post the things I think are needed to put a leaf spring SAS under a truck and make it reliable, and significantly stronger than the IFS he has under his truck now. A stock solid axle, while providing a little more clearance and articulation, is about the same strength wise as IFS. The diff itself is a good bit stronger, but the stock birfs will blow up with a 33 about as often as a CV will, and the J arm steering is at best equally as strong as the pitman idler set up on the early IFS.
So, I'm not trying to dissuade you. I'm just putting up what I would do to make the truck reliable, and strong enough that I'm not always fixing my truck on the trail constantly. I also hate doing things over and over, and I believe that putting non-reliable stuff in a truck ends up costing more than just doing the initially more expensive reliable stuff, because that has been my experience. Everytime I've put a cheap part in my truck, its cost me more money and time in the long run than a reliable part from Toyota or wherever would have cost from the get go.
Not everyone has that experience.
You will need the steering, as you can't make the stock Solid axle steering work on your truck without a whole lot more effort. If you just cleaned up the axle, stuck with stock gears, cheap shocks from Napa, no lockers, you probably would be into the swap for maybe 1000 bucks accounting for various hardware, paint, brake lines, and things you can't do without. I only posted about the ARB's because you posted up that you were thinking of using them.
Either way, I think your plan is very feasible for this winter, and I look forward to when you start the cutting!!!!
This is one of the most helpful posts I've seen on a 4wheeling site. Nicely done, and spot on, including the cost estimates. The point about spending enough to not be fixing one's junk on the trail is a great one. It's one thing to break once in awhile and be "that guy" whose breaks delay or ruin everyone's day, and I've been "that guy". It's quite another to do things on the cheap and be known as "that guy", before a trip ever starts.
You may have mentioned it before (and if you have say so, and I'll go look), but what kind of wheeling do you want to do?
Mark


Outstanding answer! Mind my $.02?
A lot - just about all - of what you want to do can be accomplished on an IFS 4Runner with 33-35" radial tires and part time lockers (e.g. ARB). You won't break much if you drive smart, which I'm guessing you do. A 4" IFS lift would be plenty, and can be installed by yourself in a weekend. The result is a very streetable, fairly low, rig that can go 99% of places. There are two downsides to IFS, IMHO:
Breakage - You can break a CV now and then, but I've seen guys replace those on a trail without too much of a problem. The 7.5" ring gear can go, too, and might be a reason to stay away from 35's.
That falling feeling - The only thing I didn't like about wheeling an IFS rig was that it spent a lot of time with one wheel off the ground, and it would sometimes "fall down" with authority. That can be a little disconcerting.
I had an 88 truck - not 4Runner - setup this way, and loved it. I always wanted a 4Runner, though, and wanted to do harder things, so I bought my SAS'd 88 4Runner. Here's what I learned in that transition, if it helps you:
A SAS'd 4Runner can be streetable. Part time lockers, good driveline angles and balanced radials are about all it takes. As I mentioned above, I got in mine in San Jose and my first drive was to Denver.
Lower is better. Mine had a 3.5-4" suspension lift and a 2" body lift, and looked like a lot of the SAS'd 4Runners you see. They look cool, but even with spacers and relatively low backspaced wheels, my 4Runner was way less stable in some situations than my IFS pickup. The thing was borderline scary off camber, in places where my truck was not. Plus, the 4Runner didn't climb anywhere near as well as my IFS pickup. Some of this was because it was unnecessarily heavy in the back, with a spare tire and hi-lift mounted on the back bumper, but some was because it was just too tall. I could have removed the body lift, but the truck had been built around it, and it did make things easy to get to. I ended up moving the tire and jack inside the cab, and moved the axle back 5" to make it climb like I wanted. That led to wider axles and 40" bias ply tires, and all of a sudden it's a trailer queen.

With regard to your concerns:
#1 - I'm no help here.
#2 - Possible, but not likely. MIG welding isn't hard, so if your friend is good at it, you're fine. Certifications mean nothing.
#3 - Not much help here, either. If we knew each other, I'd offer up my space for a day or weekend, but that's pretty ambitious for a SAS. Though our internet personas are witty and charming, that doesn't mean we wouldn't want to strangle each other in real life.
#4 - Highly unlikely. If you can ride a motorcycle without getting yourself killed, you can figure out wheeling pretty quick. There is a certain touch that good drivers have and bad ones don't, but everyone goofs up now and then, and that's part of learning.
I hope this helps.
Mark

FWIW, I used a 4" Skyjacker lift with new rear springs, but that was 16 years ago. When the time comes, you're welcome to my 33" emissions tires to check fit.
BTW, you might find that 4.10s are fine with 33's with dual cases. Mine were a little tall on the road, but not bad, and were fine on the trail after I put 4.70 gears in the case. That's pretty much what you're doing with dual cases.
Mark
It looks like Roger Brown has some new IFS goodies... http://www.4crawler.com/4x4/ForSale/ Bushings that aren't plastic!
Also these are the spacers that I've seen most people talk about regarding IFS: http://www.4crawler.com/4x4/ForSale/BallJointSpacer.shtml
Probably also would want this to protect the CV joints a bit? http://www.4crawler.com/4x4/ForSale/DiffDrop.shtml
I could go crazy with some of the things this guy did: http://forum.ih8mud.com/threads/rotbw.168936/#post-2390766
Hmm.